Low profile suspended ceiling beam

ABSTRACT

A low profile beam. This beam has a web with flanges attached to the bottom and a bulb attached to the top. The bulb is an inverted triangle connected to one edge of the web, with flanges projecting from the opposite edge of the web. The top face of the bulb is scored. In addition, the angled faces of the bulb and the flanges may be scored. The beam may be further incorporated into a ceiling system.

RELATED APPLICATION

This application claims the benefit of priority to U.S. patent application No. 62/773,591 titled Low Profile Suspended Ceiling Beam filed on Nov. 30, 2018, the contents of which are incorporated in this, application by reference.

FIELD OF THE INVENTION

This disclosure relates generally to the field of beams that are roll-formed from sheet metal and that comprise the grid of suspended ceilings and, more specifically, low profile beams that assist with fastener placement in confined spaces.

BACKGROUND OF THE DISCLOSURE

Plenums are air compartments or chambers that are found in buildings above suspended ceilings, in the gap between the suspended ceiling and the structural ceiling. They form part of the ventilation system for the building. A plenum may be supply or return plenum, and may serve either an entire building or a specific zone (e.g., floor) in a building. A supply plenum supplies ventilation air to the occupied space, while return air is generally extracted through ductwork. Conversely, in a return plenum the air is generally ducted to the space, while the return air is extracted through the plenum.

Plenums can give good flexibility for the layout of buildings. In current building designs architects are seeking to increase ceiling height without increasing floor height. This trend has led to the reduction in the size of the plenums. Unfortunately, the size of components contained within the plenum (e.g., ductwork) or the weight the suspended ceiling must support has not shrunk at the same pace. Furthermore, installers of suspended ceiling systems continue to demand that suspended ceiling systems be capable of being installed with presently established industrial installation methods.

A suspended ceiling system includes main beams and supporting cross beams connected by clips and fasteners (e.g., screws). Such beams typically may be cut to length using metal shears. The suspended ceiling system is then typically attached to the structural ceiling using brackets and fasteners. Although main beams may be routed around components (e.g., ductwork) within a plenum, cross beams typically must run under such components. To accommodate the reduction in plenum size, such cross beams must have a lower profile than the main beams while at the same time supporting similar loads and being compatible with standard industrial installation methods (e.g., the beams must have flat surfaces into which fasteners may be driven).

Therefore, there exists a need for roll-forged cross beam with a low profile that supports similar loads as the main beam and is compatible with standard industrial installation methods.

BRIEF SUMMARY OF THE DISCLOSURE

To meet this and other needs, and in view of its purposes, a low profile roll-formed steel beam with a bulb shaped like an inverted triangle and containing at least one score mark on its top face of the inverted triangle is provided. Furthermore, this beam can be installed in the same manner as prior roll-formed beams.

The disclosed beam is comprised of: (1) a web having a top and a bottom edge opposite each other; (2) two flanges opposite each other at the bottom edge that each extend out in a substantially perpendicular angle from the web; and (3) a bulb shaped like an inverted isosceles triangle and containing at least one score mark on its top face, which is further from the flanges than its angled faces. Typically, the beam is roll-formed from a single sheet of steel and connected with stitches (i.e., protuberances pushed from one side of the web through to another side).

In one embodiment, the height of the beam is less than the combined widths of the two flanges. Such dimensions may provide obstruction clearance in reduced plenum space applications while still providing increased area for fastener attachment.

In one embodiment, the width of the angled faces of the bulb is greater than the width of the top face of the bulb. Such dimensions may provide greater stability for installation of the beam or stability with regard to weight distribution.

In one embodiment, the width of the top face of the bulb is between about half the combined width of the flanges and about one sixth the combined width of the flanges. Such dimensions may provide greater stability in product packout for shipping.

In one embodiment, the top face of the bulb is scored. In another embodiment, the angled faces of the bulb are scored. In a further embodiment, the flanges are scored. Such scoring pray include indentations or apertures placed along a line and disposed substantially parallel to the length of the beam. In one embodiment such scoring is substantially centered along the length of the top face of the bulb. In another embodiment, each face includes 2, 3, or 4 scoring lines. The scoring may be located up to the edge of each face or the flange. Such scoring may assist in aligning fasteners (e.g., screws) and prevent such fasteners from wobbling or “walking” when they are driven into the beam to secure the beam to other beams or the structural ceiling.

The beam may also be incorporated into a ceiling system to form a suspended support grid which includes a plurality of intersecting grid support members arranged horizontally with grid openings formed between the grid support members. The suspended ceiling grid formed from the beams is suspended from a structural support, such as a structural ceiling, by brackets or hang wires. In one embodiment, a fastener plate or bracket is attached to the beam with a fastener. Such attachment points may be located on either the top face or angled faces of the bulb.

In one embodiment, threaded load and hang rods are secured to a suspended ceiling grid formed from the disclosed beam by clips fastened to flanges of other elements of the suspended ceiling or clips attached to elements of the structural ceiling. The clips may be spaced on the suspended ceiling at locations that maintain a level and balanced suspended ceiling. Such clips may attach to the flanges, web, or bulb of the disclosed beam. The clip may be further adapted to accept a fastener to secure the beam to the ceiling system.

A method for forming the beams is provided. The method includes providing flat coil stock that is fed into a series of rollers which: (1) draws the stock to the centerline to form the top face of the bulb; (2) forms the angled faces of the bulb; (3) bends the stock to create the web; (4) folds the edge of each side of the stock approximately ninety degrees (90°) to produce a flange; (5) folds the stock down along the two angles where the top face of the bulb contacts the angled faces of the bulb; and (6) stitches the web together forming the beam.

It is to be understood that both the foregoing general description and the following detailed description are exemplary, but are not restrictive, of the invention.

BRIEF SUMMARY OF THE SEVERAL VIEWS OF THE DRAWING

The invention is best understood from the following detailed description when read in connection with the accompanying drawing and appended claims. It is emphasized that, according to common practice, the various features of the drawing are not to scale. On the contrary, the dimensions of the various features are arbitrarily expanded or reduced for clarity. Included in the drawing are the following figures:

FIG. 1 is a perspective view of one embodiment of the beam;

FIG. 2 is a top view of the beam of FIG. 1;

FIG. 3 is a bottom view of the beam of FIG. 1;

FIG. 4 is a side view of the beam of FIG. 1;

FIG. 5 is a front view of the beam of FIG. 1;

FIG. 6 is a front view of the beam of FIG. 1 with the height of the beam of FIG. 1 identified as element B and the widths of different profile elements identified as elements A, C, and D;

FIG. 7A is a perspective view of the beam of FIG. 1 attached to a fastener plate:

FIG. 7B is a front view of the beam of FIG. 1 attached to a fastener plate;

FIG. 7C is a front view of the beam of FIG. 1 attached to an angled bracket;

FIG. 8A is a perspective view of a bracket with slide locks attached to a molding piece;

FIG. 8B is a perspective view of the beam of FIG. 1 engaged with slide locks attached to a molding piece;

FIG. 9 is one embodiment of the folds that a sheet of metal undergoes to form the beam of FIG. 1;

FIG. 10A is a perspective view of the beam of FIG. 1 installed between molding and under ductwork;

FIG. 10B is a front view of the beam of FIG. 1 installed between molding and under ductwork;

FIG. 11A is a perspective view of the beam of FIG. 1 installed between main beams and under ductwork; and

FIG. 11B is a front view of the beam of FIG. 1 installed between main beams and under ductwork.

DETAILED DESCRIPTION

The features and benefits of the disclosed beam are illustrated and described by reference to exemplary embodiments. The disclosure also includes the drawing, in which like reference numbers refer to like elements throughout the various figures that comprise the drawing. This description of exemplary embodiments is intended to be read in connection with the accompanying drawing, which is to be considered part of the entire written description. Accordingly, the disclosure expressly should not be limited to such exemplary embodiments illustrating some possible non-limiting combinations of features that may exist alone or in other combinations of features.

In the description of embodiments, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present invention. Relative terms such as “lower,” “upper,” “horizontal,” “vertical,” “above,” “below,” “up,” “down,” “top,” and “bottom” as well as derivatives thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description only and do not require that the apparatus be construed or operated in a particular orientation. Terms such as “attached,” “affixed,” “connected,” “coupled,” “interconnected,” and similar terms refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both moveable or rigid attachments or relationships, unless expressly described otherwise.

Beam Structure

FIG. 1 depicts an exemplary embodiment of the beam 100 according to the present disclosure. The beam 100 includes at least one bulb 130. The bulb 130 is connected to a vertical web 110, which has two edges (i.e., a top edge 114 and a bottom edge 112). Two flanges 120 which extend opposite each other and substantially perpendicularly out from the bottom edge 112 of the web 110, are connected to the bottom edge 112. The two sides of the web 110 are then connected by a stitch 140.

Bulb

In typical suspended ceiling beams the bulb is square or rectangular shaped. Such bulbs are only 0.25 inches (0.64 cm) wide. This width is derived from acoustical ceilings where the bulb width is limited to allow for the ceiling panels to be installed. Such reduced width extends to additional ceiling elements such as lighting fixtures and air diffusers, which are themselves sized to fit bulbs having a width of 0.25 inches (0.64 cm). The size of conventional bulbs was also adapted to drywall grid. Regardless, standard bulbs having a width of 0.25 inches (0.64 cm) do not produce a shape with adequate area moment of inertia to meet the load/deflection requirements for one layer of ⅝ inch (1.6 cm) drywall.

To reduce the profile or height of the beam 100 while still maintaining the rigidity to hold ⅝ inch (1.6 cm) drywall, the present beam utilizes a bulb 130 that has an inverted triangle shape. In such a configuration, the bulb 130 includes a top face 132 connected to two angled faces 134 each connected to the web 110. The profile of the angled faces 134 will be substantially similar, such that the top face 132 and the two angled faces 134 form an inverted isosceles triangle. In another embodiment, the width of the top face 132 will be the same as both of the angled faces 134 thereby forming an inverted equilateral triangle.

In one embodiment, the width of the top face 132 may be between 0.33 inches and 2.0 inches (0.85 cm and 5.08 cm). In another embodiment, the width of the top face 132 may be between 0.5 inches and 1.5 inches (1.27 cm and 3.81 cm). In a further embodiment, the width of the top face 132 may be between 0.6 inches and 1.0 inches (1.52 cm and 2.54 cm). Such dimensions may produce a shape with adequate area moment of inertia to meet the load/deflection requirements for one layer of ⅝ inch (1.6 cm) drywall and provide an increased surface area to attach the beam 100 to the structural ceiling.

In one embodiment, the width of each angled face 134 may be between 0.33 inches and 2.5 inches (0.85 cm and 6.35 cm). In another embodiment, the width of each angled face 134 may be between 0.5 inches and 2.0 inches (1.27 cm and 5.08 cm). In a further embodiment, the width of each angled face 134 may be between 0.6 inches and 1.5 inches (1.52 cm and 3.81 cm). Such dimensions may produce a shape with adequate area moment of inertia to meet the load/deflection requirements for one layer of ⅝ inch (1.6 cm) drywall and provide an increased surface area to attach the beam 100 to the structural ceiling. In another embodiment, the width of each angled face 134 may be greater than the width of the top face 132.

To assist in securing the beam 100 to the structural ceiling, in one embodiment the top face 132 has a score line 136. The score line 136 may assist in aligning fasteners 600 (e.g., screws) or prevent such fasteners 600 from wobbling or “walking” when they are driven into the beam 100 to secure the beam 100 to other beams or the structural ceiling. The score line 136 may be located along a centerline of the length of the top face 132. In other embodiments, the top face 132 may contain two or more scoring lines 136, each located a substantially equal distance from the centerline of the length of the top face 132.

In one embodiment, the scoring lines 136 comprise protuberances projecting towards the flanges 120. In another embodiment, the scoring lines 136 comprise protuberances projecting away from the flanges 120. In a further embodiment, the scoring line comprise apertures through the surface of the top face 132. Such apertures may define a circle, square, or diamond shape.

In another embodiment one or both of the angled faces 134 have a score line 136. Such score line 136 may be located along a centerline of the length of the angled face 134. In other embodiments, the angled face 134 may contain two or more scoring lines 136, each located a substantially equal distance from the centerline of the length of the angled face 134.

In one embodiment, the scoring lines 136 comprise protuberances projecting towards the top face 132. In another embodiment, the scoring lines 136 comprise protuberances projecting away from the top face 132. In a further embodiment, the scoring lines 136 comprise apertures through the surface of the angled face 134. Such apertures may define a circle, square, or diamond shape.

Web

In FIG. 5 a dual web 110 comprised of two vertical sheets stitched together is disclosed. The vertical sheets comprise two surfaces opposite one another. The first surface 512 is stitched to the second surface 514 by forcing a portion of the first surface 512 through a portion of the second surface 514 creating a protuberance 510 in the second surface 514. It is further understood that the web 110 may be comprised of a single sheet or multiple sheets (e.g., two, three, or four sheets) of material.

In one embodiment the height of the web 110 is greater than 0.25 inches (0.64 cm).

In another embodiment the sum of the height of the web 110 and the height of the bulb 130 is less than the combined width of the flanges 120, and the width of the top face 132 is greater than 0.25 inches (0.64 cm) and equal to or less than the width of one flange 120. Such dimensions may assist in packing, storing, or stacking the beams 100.

Flanges

In one embodiment, the edges of the flanges 120 are folded back over each other. In one embodiment, the edge of the flange 120 is folded back over itself in the direction of the web 110. In another embodiment, the edge of the flange 120 is folded back over itself in the direction opposite the web 110.

To assist in securing the beam 100 to a ceiling system, in one embodiment the flanges 120 have score lines 136. Such score lines 136 may assist in aligning fasteners 600 (e.g., screws) or prevent such fasteners 600 from wobbling or “walking” when they are driven into the beam 100 to secure the beam 100 to other beams or the ceiling system. Such score lines 136 may be located along a centerline of the length of the flanges 120. In other embodiments, the flanges 120 may contain two or more scoring lines 136, each located a substantially equal distance from the centerline of the length of the flange 120.

In another embodiment, a cap 150 is added to the bottom of the flanges 120 and wrapped around to the top of the flanges 120. Preferably the cap 150 is a separate piece of material. The cap 150 may also be an extension of one or both of the flanges 120.

Beam Manufacture

FIG. 9 depicts the manufacture of an exemplary embodiment of the beam 100. The beam 100 is manufactured using a roll-forming process. The process begins with a flat material (e.g., metal, polymer, or carbon fiber) stock 900 that is fed into a series of rolls. The dimensions of the top face 132 and angled faces 134 may be formed first. In the subsequent roll passes, the outer edges of the stock 900 may be formed to provide the web 110 and flanges 120. The outer edges of the stock 900 may then be folded down at the intersection of the top face 132 and the angled faces 134 to fold the stock 900 vertically. Additional forming provides the score lines 136 of the bulb 130. The first surface 512 is then punched through the second surface 514 forming indentations 516 in the first surface 512 and the protuberances 510 in the second surface 514 (i.e., a stitch). This stitch locks the material together. A painted or unpainted strip used to form the flange cap 150 may then be introduced to the face of the beam 100 (i.e., the bottom of the flanges 120). The edges of the cap 150 are then be folded over the edges of the flanges 120 to form a hem and lock the flange cap 150 onto the beam 100. The beam 100 is then straightened to equalize the stresses introduced in the forming process and cut off to length. Secondary processing may be completed in a press to add end details, routs, and wire holes. With or without this secondary process, the result is a complete, saleable product.

Beam Materials

It will be understood that the beam 100 may be constructed out of any bendable material such as metals, polymers, or carbon fiber. In one embodiment, the beam 100 is manufactured from metal. For example, the beam 100 may be is manufactured from rolled steel.

Beam Dimensions

FIG. 6 depicts different embodiments of the profile ratios of the beam 100. In one embodiment, the height of the beam 100 (identified as distance “B”) is less than the combined widths of the two flanges 120 (identified as distance “A”). Such a profile may provide obstruction clearance in reduced plenum space applications while still providing increased area for fastener attachment. In another embodiment, the width of the top face 132 (identified as distance “D”) is between about half the combined width of the flanges 120 and about one sixth the combined width of the flanges 120. Such dimensions may provide greater stability in product packout for shipping. In another embodiment, the width of the angled faces 134 (identified as distance “C”) is greater than the width of the top face 132 (identified as distance “D”). Such dimensions may provide greater stability for installation of the beam or stability with regard to weight distribution.

Each flange 120 of the beam 100 may have a width of between approximately 0.5 inches (1.27 cm) and 2.00 inches (5.08 cm). In one embodiment, the individual flange width of the beam 100 is between approximately 1.0 inches (2.54 cm) and 1.75 inches (4.45 cm). In another embodiment, each individual flange width is about 1.5 inches (3.81 cm). In such an embodiment, the combined flange width (identified as distance “A”) may be 3.0 inches (7.62 cm). It will be further understood that the inclusion of the cap 150 may further increase the width of the flanges 120 of the beam 100.

The material gauge from which the beam 100 may be constructed may be between approximately 0.008 inches (0.020 cm) and 0.05 inches (0.127 cm). In one embodiment, the material gauge is between approximately 0.01 inches (0.025 cm) and 0.018 inches (0.046 cm).

Incorporation into a Ceiling System

The disclosed beam 100 may be incorporated into a low profile ceiling system grid framework. In another embodiment, shown in FIGS. 10A and 10B the beam 100 is attached to a molding 800 using a fastener 600. In yet another embodiment, shown in FIGS. 11A and 11B the beam 100 is attached to a main beam 830. Such a system may permit the beam 100 to run underneath obstructions 1000 within the plenum while still minimizing the plenum space.

In one embodiment, the molding 800 or main beam 830 includes a pocket 810 and a protuberance 820. FIGS. 8A and 8B depict one such embodiment. The protuberance 820 may project outward from the molding 800 or main beam 830 in a direction substantially parallel to the length of the molding 800 or main beam 830. In one embodiment, the protuberance 820 may include a pointed or serrated edge. The pocket 810 and the protuberance 820 may also be punched out of the molding 800 or main beam 830. In such an embodiment, the beam 100 may be slid into the pocket 810 and then back against the protuberance 820 in a direction substantially opposite the direction of the projection of the protuberance 820 thereby locking the beam 100 in place.

In creating the ceiling system, an installer first forms a grid framework with tessellation (i.e., a pattern of flat shapes with no overlaps or gaps). The tessellations may be a regular tessellation (i.e., repeating regular polygons such as triangles, squares, rectangles, hexagons, etc.) or semi-regular tessellations (i.e., a grid made of two or more regular polygons such as hexagons/triangles, triangles/squares, hexagons/squares/triangles, octagons/squares, etc.).

The grid is suspended from a structural support, such as a structural ceiling, by hang wires or hang rods located above the grid of beams 100. Panels may also be placed in the grid openings or drywall attached to the grid face.

In other embodiments, as shown in FIG. 7C, the grid or beams 100 may be attached to a structural ceiling 870 with brackets 850. Such brackets 850 may be angled. The brackets 850 may also be attached to the beam 100 using fasteners 600 driven through the top face 132 and/or one or both of the angled faces 134. A tool (e.g., a drill) 860 may be used to drive the fasteners 600.

The load and hang clips may be further spaced on the suspended ceiling at locations that maintain the level and balance of the suspended ceiling. In one embodiment, the suspended ceiling may remain balanced, level, and intact even though the load below the grid of beams 100 is not spread evenly over the grid of beams 100.

As can be seen, the inclusion of the scoring lines 136 allows for the precise fastening of the beam 100 to the suspended ceiling or to other beams while at the same time minimizing the requirements for the incorporation of additional material (i.e., minimizing costs).

Although illustrated and described above with reference to certain specific embodiments and examples, the present invention is nevertheless not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the spirit of the invention. It is expressly intended, for example, that all ranges broadly recited in this document include within their scope all narrower ranges which fall within the broader ranges. It is also expressly intended that the steps of the methods of using the various devices disclosed above are not restricted to any particular order. 

What is claimed is:
 1. A beam for a suspended ceiling, comprising: a web having a first edge opposite a second edge; a bulb having: a top face having a scoring line substantially parallel to the web and located along the length of the top face, and two angled faces of substantially equal width, each in contact with the first edge of the web and the top face, wherein the top face and angled faces form an inverted triangle; and two flanges opposite one another at the second edge of the web extending substantially perpendicularly out from the web.
 2. The beam of claim 1, wherein the top face and angled faces define an equilateral triangle.
 3. The beam of claim 1, wherein the angled faces include scoring lines substantially parallel to the web and located along the length of the angled faces.
 4. The beam of claim 1, wherein the flanges include scoring lines substantially parallel to the web and located along the length of the flanges.
 5. The beam of claim 1, wherein the height of the beam is less than the combined widths of the two flanges.
 6. The beam of claim 1, wherein the width of one of the angled faces of the bulb is greater than the width of the top face of the bulb.
 7. The beam of claim 1, wherein the width of the top face of the bulb is between about half the combined width of the flanges and about one sixth the combined width of the flanges.
 8. The beam of claim 1, wherein the beam is formed from a single sheet of material.
 9. The beam of claim 8, wherein the beam is formed from one or a combination of metals, polymers, and carbon fiber.
 10. The beam of claim 8, wherein the material has a thickness of between about 0.008 inches and about 0.05 inches.
 11. The beam of claim 1, wherein the web is comprised of a first surface substantially parallel to a second surface wherein the first surface and the second surface are joined together by a stitch.
 12. The beam of claim 11, wherein the stitch comprises a portion of the first surface which passes through a portion of the second surface creating an indentation in the first surface and a protuberance in the second surface.
 13. A suspended ceiling configured for location proximate a plenum space, the ceiling comprising: a grid formed of main beams running substantially parallel to one another connected by cross beams, wherein the cross beams include: a web having a first edge opposite a second edge; a bulb having; a top face having scoring line substantially parallel to the web and located along the length of the top face, and two angled faces of substantially equal width, each in contact with the first edge of the web and the top face, wherein the top face and angled faces form an inverted triangle; and two flanges opposite one another at the second edge of the web extending substantially perpendicularly out from the web, wherein the grid is adapted to maximize the plenum space.
 14. The suspended ceiling of claim 13, wherein the suspended ceiling remains balanced, level, and intact even though a load below the grid of beams is not spread evenly over the grid of beams.
 15. The suspended ceiling of claim 14, wherein the web is comprised of a first surface substantially parallel to a second surface wherein the first surface and the second surface are joined together by a stitch.
 16. The suspended ceiling of claim 15, wherein the stitch comprises a portion of the first surface which passes through a portion of the second surface creating an indentation in the first surface and a protuberance in the second surface. 